106676-2661 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066762661 me444776

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106676-2661 1066762661

MITSUBISHI ME444776 me444776

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Cross reference number

ZEXEL 106676-2661 1066762661

MITSUBISHI ME444776 me444776

Zexel num

Bosch num

Firm num

Name

106676-2661

ME444776 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D24

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131424-4620

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 9.1

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 85 82 88

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9.5 6.9 12.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 100 90 110

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 650--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 2.5 2 3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Torque spring does not operate. (4)RACK LIMIT (5)The torque control spring must does not have a set force. (6)Idle sub spring setting: L1.
----------
K=15 L1=4.5-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(22deg)+-5deg b=(8deg)+-5deg

Stop lever angle

N:Normal S:Stop the pump.
----------

----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(5deg)

Information:

start by: a) separation of governor from fuel injection pump housing1. Remove the cover (16) from rack centering pin. Move the rack to the fuel "OFF" position, and push in on the centering pin (15). Install the cover (16) as shown to keep the centering pin in position during disassembly and assembly of injection pump housing. 2. Move the rack toward the fuel "ON" position until the slot in rack (13) is against the rack centering pin (15). The rack is now in the "CENTER" position.
Do not try to remove the fuel injection pumps if the rack is not in "CENTER" position.
3. Remove the fuel injection pumps as follows: a) Remove the caps and felt washer (1).b) Install wrench (A), and remove the bushing (2) from housing. c) Install extractor (B).d) Remove the bushing (2) and wrench (A).e) Remove the seal (3).f) Lift the fuel injection pump up and out of housing.g) Remove the spacer (9). Keep the spacer (9) together with its respective fuel injection pump. Put identification on the pumps and spacers as to their location in the pump housing.4. Disassemble the fuel injection pumps as follows: a) Remove the ring (7), bonnet (4), check valve (6), and spring (5) from barrel (8).b) Remove the plunger assembly (11), washer (12), and spring (10) from barrel (8).
Be very careful when disassembling and assembling the fuel injection pumps to prevent damage to the plunger surfaces. The barrel and plunger assemblies are fitted together, and must not be used with other barrels or plunger assemblies.
5. Remove the rack centering pin, spring, and cover. 6. Remove the rack (13), and lifters (14). Put identification on the lifters as to their location in the pump housing. Keep the lifters with their respective pumps and spacers. 7. Remove the bolt, lock, and plate (17) from the camshaft. Remove the spring and gear assembly (18).8. Remove the camshaft (20) from pump housing.9. Remove the rack bearings (19) from housing. 10. Use tool setup (C) to remove the camshaft bearings from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Use tool group (D) to install the rack bearing in the accessory drive housing end of injection pump housing.2. Install the rack bearing in governor end of housing using tool setup (E). The bearing must be installed .195 .005 in. (4.95 0.13 mm) below outside face of pump housing.3. Use tool group (C) to install the camshaft bearings in housing. Make sure the oil holes in bearings are in alignment with oil holes in pump housing. 4. Put clean engine oil on the camshaft bearings. Install the camshaft (1) in pump housing. 5. Install the gear (3), spring, plate, lock, and bolt (2) on the camshaft.6. Put clean engine oil on lobes of camshaft. 7. Install the lifters (4) in their respective positions in pump housing. Install the spacers in their correct locations in housing. If new lifters are to be installed, it will be necessary to check the timing